12-16-2007, 06:01 AM
John,
These directions are liberally stolen from Matt Amt, any mistakes are my own.
Look in your yellow pages for a wood supply stores. Call around and find one that sells 1/8 inch luan ply. At one local shop here in Metro Detroit is was $15 for a four foot by eight foot sheet. They have very large saws at these places and most will give you a certain number of cuts for free. All you need is three. If you do not want to be really accurate just have them cut the board in half, and then cut each half in half again. If yo want to get something a little closer to the toughness of the Roman design have them cut the second cuts one with, and one against the grain. In any event you will end up with four 2'x4' sheets each 1/8 inch thick.
Next obtain two "come alongs" (sorry I have no other idea on what these might be called) the ratcheting nylon belts. Also obtain a gallon of wood glue (what you do not use forming the shield you will use getting the felt glued on later). You will also need the assistance of two 2x4's or even 2x2's will do, but they need to be about four feet long each (basically the same length as the cut down pieces of luan ply and at least one friend/assistant. Finally find a big tree, aim for at least four feet around, either in your own yard, or that someone who will let you use their tree for a few days.
Take one piece of Luan and lay it down. Lay on a heavy coat of the glue on this sheet. Lay a second piece of the Luan over the first. Note if you bothered to have two pieces that are cut with the grain and two that are cut against the grain take one of these pieces from each group. Now just lay the 2x4 or 2x2's on the two pieces of luan with the glue between them. DO NOT GLUE THE 2x4/2x2 TO THE LUAN, just lay them on top and on either side. Have your assistance pick up the sandwich of luan and glue and hold it against the tree selected. Take the first "come along" and place it around the tree and over the glued Luan and 2x4's and tighten the "come along", not really tight, but tight enough to hold the entire operation to the tree. Now repeat the above with the second "come along". Next, you are almost done have you and your assistant make sure theat the two come alongs are seperated, put the first about a third of the way down the luan from the top, and the second about two thirds of the way down. Now, each of you tighten a "come along" Work together and do them more or less at the same time, it is not likely, but you can split the luan if you tighten it too fast. Once you have it tightened up snug to the curve of the tree all you have to do is go away and leave it alone for two or three days to dry. After the glue dries the luan will be the right depth and basically the right shape. If you use the same tree all of your shields will take the same basic shape.
Now it is just: inner liner, outer liner, center grip, umbo, paint and design and you have your shield. Oh yeah, and maybe edging too.
Enjoy,
Cordially,
Michael
These directions are liberally stolen from Matt Amt, any mistakes are my own.
Look in your yellow pages for a wood supply stores. Call around and find one that sells 1/8 inch luan ply. At one local shop here in Metro Detroit is was $15 for a four foot by eight foot sheet. They have very large saws at these places and most will give you a certain number of cuts for free. All you need is three. If you do not want to be really accurate just have them cut the board in half, and then cut each half in half again. If yo want to get something a little closer to the toughness of the Roman design have them cut the second cuts one with, and one against the grain. In any event you will end up with four 2'x4' sheets each 1/8 inch thick.
Next obtain two "come alongs" (sorry I have no other idea on what these might be called) the ratcheting nylon belts. Also obtain a gallon of wood glue (what you do not use forming the shield you will use getting the felt glued on later). You will also need the assistance of two 2x4's or even 2x2's will do, but they need to be about four feet long each (basically the same length as the cut down pieces of luan ply and at least one friend/assistant. Finally find a big tree, aim for at least four feet around, either in your own yard, or that someone who will let you use their tree for a few days.
Take one piece of Luan and lay it down. Lay on a heavy coat of the glue on this sheet. Lay a second piece of the Luan over the first. Note if you bothered to have two pieces that are cut with the grain and two that are cut against the grain take one of these pieces from each group. Now just lay the 2x4 or 2x2's on the two pieces of luan with the glue between them. DO NOT GLUE THE 2x4/2x2 TO THE LUAN, just lay them on top and on either side. Have your assistance pick up the sandwich of luan and glue and hold it against the tree selected. Take the first "come along" and place it around the tree and over the glued Luan and 2x4's and tighten the "come along", not really tight, but tight enough to hold the entire operation to the tree. Now repeat the above with the second "come along". Next, you are almost done have you and your assistant make sure theat the two come alongs are seperated, put the first about a third of the way down the luan from the top, and the second about two thirds of the way down. Now, each of you tighten a "come along" Work together and do them more or less at the same time, it is not likely, but you can split the luan if you tighten it too fast. Once you have it tightened up snug to the curve of the tree all you have to do is go away and leave it alone for two or three days to dry. After the glue dries the luan will be the right depth and basically the right shape. If you use the same tree all of your shields will take the same basic shape.
Now it is just: inner liner, outer liner, center grip, umbo, paint and design and you have your shield. Oh yeah, and maybe edging too.
Enjoy,
Cordially,
Michael
Mediocris Ventvs Qvod Seqvax Maris
Michael
Michael
